Cover for fluid systems and related methods

ABSTRACT

Embodiments of a high-pressure, high power, reciprocating positive displacement fluid pumping system and methods are included. The system may include a high-pressure, high power, reciprocating positive displacement pump including a pump plunger, a fluid end block assembly, and a fluid cover. The fluid end block assembly may include a fluid end block body, a suction port, a discharge port, a pump bore positioned in and extending through the fluid end block body, and a fluid chamber positioned in the fluid end block body and in fluid communication with each of the suction port, the discharge port, and the pump bore. The fluid chamber has an open end portion, and the pump plunger may be positioned to move in the pump bore to pressurize one or more fluids in the fluid chamber. The fluid cover includes a monolithic body having a first portion and a second portion, the first portion being received in the open end portion and sealably engaged with the fluid end block body, the second portion being mechanically connected to the fluid end block body.

BACKGROUND OF THE DISCLOSURE

The present disclosure generally relates to pressurized fluid systems,fluid end covers, and methods, for example, high pressure single actingreciprocating pumping systems and methods such as those that includehydraulic fracturing single acting reciprocating pumps. Specifically,the present disclosure relates to a fluid cover for a fluid end blockassembly of hydraulic fracturing pumping systems.

Hydraulic fracturing often is used to produce oil and gas in an economicmanner from low permeability reservoir rocks, such as shale. Hydraulicfracturing restores or enhances productivity of a well by creating aconductive flow path of hydrocarbons between the reservoir rock and awellbore. During hydraulic fracturing, a fluid initially is pumped underhigh pressure to fracture rock in a reservoir formation and open a flowchannel. Thereafter, a proppant-carrying fluid, e.g., a fluid thatcomprises proppant in the form of granular solid and/or semi-solidcomponents, e.g., sand, ceramics, is pumped to continue opening andwidening the flow channel while suspending proppant inside it. Theproppant thus keeps the flow path opened for the hydrocarbons to flow.

Hydraulic fracturing treatments may be performed using single actingreciprocating fracturing pumps to deliver fluids at a high pressure,specifically, above the fracture pressure of the rock in a reservoirformation. These fracturing pumps are of a type referred to asreciprocating plunger pumps. Such pumps may have multiple pumps, forexample, 3 or 5 plungers to form “triplex” and “quintuplex” pumps,respectively. In such pumps, one or more plungers moves linearly backand forth in a cylindrical bore, traveling in and out of a pump fluidchamber. The fluid chamber is in communication with a suction or intakeport and discharge port. Each port may include additional fluid handlingcomponents, for example, springs and valves (such as a one-way valve).

In this regard, fluid enters the chamber through the suction port as theplunger withdraws from the chamber. It is then pumped out of the chamberthrough the discharge port as the plunger enters the chamber.

The plungers are part of what is generally referred to as the fluid endof the pumping system, a major component of which is a pump housing orfluid end block assembly. Accordingly, the fluid end block assembly mayinclude passages or bores, e.g., cylindrical bores, in which theplungers travel, and within which valves, suction and discharge ports,fluid covers and other closures, etc., may be positioned.

The cyclic movement of the plungers may forcibly pressurize fluidsinside the fluid end block assembly of the pumping system. The ruggedenvironments, high pressure of the fluid, and high power operations ofthe pumps causes fluid ends to become damaged, broken, and unusable, maydecrease the usable life of the fluid ends, and may cause operationaldowntime or increased costs associated with pumping system operations ata well site.

SUMMARY OF THE DISCLOSURE

In view of the foregoing, there is an ongoing need for enhanced pumpingsystem components and methods more suitable for use in the fluid endblock assembly of a pumping system when being used in the associatedrugged environments, as well as for high pressure and high poweroperations.

According to one embodiment of the disclosure, a high-pressure, highpower, reciprocating positive displacement fluid pumping system mayinclude a high-pressure, high power, reciprocating positive displacementpump having a pump plunger, a fluid end block assembly, and a fluidcover. The fluid end block assembly, for example, may include a fluidend block body, a suction port, a discharge port, a pump bore positionedin and extending through the fluid end block body, and a fluid chamberpositioned in the fluid end block body and in fluid communication witheach of the suction port, the discharge port, and the pump bore. Thefluid chamber has an open end portion, and the pump plunger ispositioned to move in the pump bore to pressurize one or more fluids inthe fluid chamber. An embodiment of the fluid cover, for example, mayhave a monolithic body including a first portion and a second portion.The first portion may be received in the open end portion and sealablybe engaged with the fluid end block body. The second portion may beconnected mechanically to the fluid end block body. The fluid cover mayinclude a shoulder that is positioned between the first portion and thesecond portion. The shoulder may be engaged with the fluid block endbody to seal the open end portion. In some embodiments, the shoulder mayinteract with the open end portion to align the fluid cover with theopen end portion.

According to another embodiment of the disclosure, a fluid end blockassembly for a high-pressure, high power, reciprocating positivedisplacement fluid pumping system may include a fluid end block body, apump bore positioned in and extending through the fluid end block body,a plurality of ports including a suction port and a discharge port whichcollectively provide access to and from the pump bore, and a fluidchamber positioned in the fluid end block body. The fluid chamber may bepositioned in fluid communication with each of the suction port, thedischarge port, and the pump bore. The fluid chamber, for example, hasan open end portion, and the pump bore may be positioned to receive amovable pump plunger to pressurize one or more fluids when located inthe fluid chamber. A fluid cover may be connected to the fluid end blockbody, and the fluid cover may include a monolithic body having a firstportion and a second portion. The first portion may be received in theopen end portion and may be configured to align the fluid cover with theopen end portion. The second portion may be connected mechanically tothe fluid end block body.

According to yet another embodiment of the disclosure, a fluid cover forbeing sealably engaged with a fluid end block assembly of ahigh-pressure, high power, reciprocating positive displacement fluidpumping system may include a monolithic body with a first portion and asecond portion. The first portion, for example, may be received in anopen end portion of a fluid chamber of the fluid end block assembly andsealably may be engaged with the fluid end block assembly. The firstportion may be configured to engage the open end portion of the fluidchamber to align the fluid cover with the open end portion. The secondportion may be connected mechanically to the fluid end block assembly.

An embodiment of the disclosure also provides a method of operating ahigh-pressure, high power, reciprocating positive displacement fluidpumping system that includes obtaining a fluid end block assembly thathas a fluid end block body, suction port, a discharge port, a pump borepositioned in and extending through the fluid end block body, and afluid chamber positioned in the fluid end block body and in fluidcommunication with each of the suction port, the discharge port, and thepump bore. The fluid chamber may have an open end portion. The methodfurther may include obtaining a high-pressure, high power, reciprocatingpositive displacement pump that has a pump plunger and fluidlyconnecting the pump to the fluid end block assembly. The method mayinclude aligning a fluid cover with the fluid end block by inserting afirst portion of the fluid cover into the open end portion. The firstportion may engage the open end portion to align the fluid cover withthe fluid end block. The fluid cover may include a monolithic bodyincluding the first portion and a second portion. The method furtherincludes sealably connecting the fluid cover to the fluid end block bymechanically connecting the second portion to the fluid end block body.The method further may include operating the pump. The operating of thepump includes moving the pump plunger in the pump bore to pressurize oneor more fluids in the fluid chamber.

An embodiment of the disclosure also provides a method of assembly afluid pumping system that includes inserting a first portion of a fluidcover into an open end portion of a fluid end block assembly andmechanically connecting a second portion of the fluid cover to the openend portion. The first portion may engage the fluid end block assemblyto align the fluid cover with the open end portion. The fluid cover maycomprise a monolithic body having the first and second portion.Mechanically connecting the second portion of the fluid cover mayinclude the first portion sealing the open end portion of the fluid endblock.

Those skilled in the art will appreciate the benefits of variousadditional embodiments reading the following detailed description of theembodiments with reference to the below-listed drawing figures. It iswithin the scope of the present disclosure that the above-discussedaspects be provided both individually and in various combinations.

BRIEF DESCRIPTION OF THE DRAWINGS

According to common practice, the various features of the drawingsdiscussed below are not necessarily drawn to scale. Dimensions ofvarious features and elements in the drawings may be expanded or reducedto more clearly illustrate the embodiments of the disclosure.

FIG. 1A is a schematic diagram of showing a layout of a fluid pumpingsystem according to an embodiment of the disclosure.

FIG. 1B is an enlarged, sectional view of a fluid end block assembly ofthe fluid pumping system of FIG. 1A according to an embodiment of thedisclosure.

FIG. 2A is a perspective view of a fluid cover component of aconventional fluid cover assembly according to an embodiment of thedisclosure.

FIG. 2B is a side view of the fluid cover component of FIG. 2A accordingto an embodiment of the disclosure.

FIG. 3A is a perspective view of a retainer component of a conventionalfluid cover assembly according to an embodiment of the disclosure.

FIG. 3B is a side view of the retainer component of FIG. 3A according toan embodiment of the disclosure.

FIG. 4 is an enlarged, sectional view of an operation of the fluid endblock assembly of FIG. 1B according to an embodiment of the disclosure.

FIG. 5 is another enlarged, sectional view of the fluid end blockassembly of FIG. 1B according to an embodiment of the disclosure.

FIG. 6A is a perspective view of an integrated fluid cover according toa first exemplary embodiment of the disclosure.

FIG. 6B is a side view of the integrated fluid cover of FIG. 6Aaccording to an embodiment of the disclosure.

FIG. 6C is a top view of the integrated fluid cover of FIG. 6A accordingto an embodiment of the disclosure.

FIG. 7A is a side view of an integrated fluid cover according to asecond exemplary embodiment of the disclosure.

FIG. 7B is another side view of the integrated fluid cover of FIG. 7A,with a seal member shown in cross-section according to an embodiment ofthe disclosure.

FIG. 8 is a sectional view of the integrated fluid cover of FIG. 7Asealably coupled with a fluid end block assembly of a fluid pumpingsystem according to an embodiment of the disclosure.

FIG. 9 is a side view of an integrated fluid cover according to a thirdexemplary embodiment of the disclosure.

FIG. 10 is a sectional view of the integrated fluid cover of FIG. 9sealably coupled with a fluid end block assembly of a fluid pumpingsystem according to an embodiment of the disclosure.

Corresponding parts are designated by corresponding reference numbersthroughout the drawings.

DETAILED DESCRIPTION

The embodiments of the present disclosure are directed to pressurizedfluid systems, for example, high pressure single acting reciprocatingpumping systems such as those that include hydraulic fracturing singleacting reciprocating pumps. In particular, the embodiments of thepresent disclosure are directed to fluid covers for use with suchpressurized fluid systems.

FIG. 1A illustrates a schematic view of a high-pressure, high power,reciprocating positive displacement fluid pumping system 100 accordingto an embodiment of the disclosure. The diagram of the system 100 showsa typical pad layout for a fracturing pump system, and the system 100includes a plurality of fracturing or frac pumps or pumping units FP1,FP2, FP3, FP4, FP5, FP6, FP7, FP8 with the pumping units all operativelyconnected to a manifold M that is operatively connected to a wellhead W.By way of an example, in order to achieve a maximum rated horsepower of24,000 HP for the pumping system 100, a quantity of eight (8) 3000horsepower (HP) pumping units may be used. It will be understood thatthe fluid pumping system 100 may include associated service equipmentsuch as hoses, connections, and assemblies, among other devices andtools. Each of the pumping units FP1, FP2, FP3, FP4, FP5, FP6, FP7, FP8may include a fluid end block assembly 101.

FIG. 1B illustrates a portion of a fluid end block assembly 101 of theembodiment of the fluid pumping system 100 as shown in a sectional view.In one embodiment, the fluid end block assembly 101 may be in fluidcommunication with and/or may form a portion of the manifold M. In thisregard, one or more of the frac pumps or pumping units FP1, FP2, FP3,FP4, FP5, FP6, FP7, FP8 may be fluidly coupled to the fluid end blockassembly 101.

The fluid end block assembly 101, as shown, includes a fluid end blockbody 121 having intersecting horizontal and vertical bore passages thatare each in fluid communication with a fluid end chamber 105 in thefluid end block body 121. The vertical bore passage includes an intakeport or suction port 102. The fluid may enter the fluid end block body121 from an intake source, for example, a fluid supply manifold. Thevertical bore passage also includes an outlet port or discharge port 103through which fluid may exit the fluid end block body 121 or flow toanother portion of the fluid end block assembly 101. One or both of thesuction port 102 and the discharge port 103 thus collectively provideaccess to and from the fluid end chamber 105 and may include fluidhandling elements or components such as seats, valves, springs, and soforth, as will be understood by those skilled in the art.

The discharge port 103, as shown, includes a discharge bore 104, e.g.,an opening or fluid channel, through which pressurized fluid may exitthe fluid end block assembly 101 to downstream components of the fluidpumping system coupled to the fluid end block assembly 101. A dischargecover assembly or discharge cap assembly 116 may be coupled to a portionof the discharge port 103, as described further herein.

As shown, a piston/plunger 107 (broadly, “pump member”) is positioned ina pump bore 108 along the horizontal bore of the fluid end blockassembly 101. The plunger 107 is movable in the pump bore 108, forexample, via reciprocating actuation of one or more of the pumping unitsFP1, FP2, FP3, FP4, FP5, FP6, FP7, FP8, with a forward stroke in thedirection of the fluid chamber 105 and that terminates proximate thefluid chamber 105, and a rearward stroke in a direction away from thefluid chamber 105 and opposite the direction of the forward stroke. Oneor more of the pumping units FP1, FP2, FP3, FP4, FP5, FP6, FP7, FP8 mayactuate the plunger 107 to move/reciprocate in the pump bore 108, forexample, via a controller or control system, as will be understood bythose skilled in the art, that may be in electronic communication withone or more of the pumping units, and which may be operated under manualand/or processor control.

As shown, the forward stroke of the plunger 107 terminates opposite anopen end portion 106 of the fluid chamber 105. In one embodiment, theopen end portion 106 of the fluid chamber 105 is positioned in a portionof the fluid end block body 121 that includes an oblique or chamferedsurface 123 that extends toward an interior threaded portion 127 of thefluid end block body 121 along interior peripheries of the open endportion 106 of the fluid chamber 105 (see FIG. 5).

A fluid cover assembly 109 (broadly, “suction cap assembly” or “suctioncover assembly” or “intake cap assembly” or “intake cover assembly”) maybe sealingly engaged with and coupled to the fluid end block body 121,as described further herein.

An embodiment of the fluid cover assembly 109 may include a fluid covercomponent 110 having a generally cylindrical body with a flanged head111 including a tool engagement feature 113 for being engaged by a toolto place, position, help secure to, and/or remove the fluid covercomponent 110 from the end portion 106 of the fluid chamber 105 (seeFIGS. 2A-2B and 3A-3B). In this regard, the fluid cover component 110may be at least partially received within the end portion 106 of thefluid chamber 105 opposite the reciprocating path of the plunger 107. Asealing member 114, e.g., a rubber or other polymeric annular seal, maybe positioned on the cylindrical body of the fluid cover component 110.

The fluid cover component 110 may be at least partially received in theend portion 106 of the fluid chamber 105, and the fluid cover assembly109 may be mechanically connected to the fluid end block assembly 101via the mechanical connection of a retainer component 112 to the fluidend block body 121.

The retainer component 112, as shown in FIGS. 3A and 3B, may be aretainer nut or other fastener having a generally cylindrical body withan outer surface that defines a threaded portion 126 that is configuredto threadably engage the corresponding interior threaded portion 127 ofthe fluid end block body 121. In this regard, the retainer component 112may be threadably advanced into the end portion 106 of the fluid chamber105 to abut the flanged head portion 111 of the fluid cover component110, for example, such that an end of the retainer component 112contacts the head portion of the fluid cover component 112 at aninterface, e.g., a discontinuity between the material of the fluid covercomponent 110 and the material of the retainer component 112. As shown,the retainer component 112 may also define a tool engagement feature 117for being engaged by a tool to place, position, and/or remove theretainer component 112 from the end portion 106 of the fluid chamber105.

It will be understood that the discharge cap/cover assembly 116 of thedischarge port 103 may have a configuration that is generally similar tothe configuration of the fluid cover assembly 109 positioned at the openend portion 106 of the fluid chamber 105 near the suction port 102. Thedischarge cap/cover assembly 116 of the discharge port 103 may have adifferent configuration without departing from the disclosure.

Referring to FIG. 4, fluid may be delivered via the suction port 102,for example, from a pump suction manifold and valve assembly, into thefluid chamber 105. The fluid in the fluid chamber 105 may be compressedby the plunger 107 upon a compression or delivery stroke, e.g., towardthe fluid chamber 105.

In the embodiment illustrated in FIG. 4, the full extension length ofthe plunger 107 may extend at least partially toward the fluid chamber105 to compress fluids disposed therein. In this regard, as the plunger107 commences its delivery or compression stroke, the fluid positionedinside of the fluid end chamber 105 is compressed by the plunger 107 andsuch compression forces are translated into the surrounding walls of thefluid chamber 105. As the end portion 106 of the fluid chamber 105 isclosed by the fluid cover assembly 109 sealingly engaged with the fluidend block body 121, the pressurized fluid in the fluid end chamber 105flows into the discharge port 103, and out the discharge bore 104.

Following/preceding the above-described compression or delivery strokeof the plunger 107, in an intake or suction stroke, the plunger 107translates along the pump bore 108 of the fluid end block assembly 101away from the fluid chamber 105 to create a suction, e.g., negativepressure or vacuum, in the fluid chamber 105 that draws additional fluidinto the fluid chamber 105 in preparation for a subsequent compressionor delivery stroke.

Referring to FIGS. 6A-6C, an integrated fluid cover according to a firstexemplary embodiment of the disclosure is generally designated 221, andmay be used in a fluid pumping system that may be otherwise similar tothe fluid pumping system 100 described above.

In the illustrated embodiment, the integrated fluid cover 221 includes amonolithic body 223, e.g., a body monolithically formed of a singlecontinuous piece or block of material that has a unitary configurationso as to be free from any seams or discontinuities that extend from anouter surface of the body 223 to an interior portion of the body 223. Itwill be understood that the body 223 of the integrated fluid cover 221may include metallic, polymeric, and/or composite materials.

The body 223 of the integrated fluid cover 221 defines a fluid coverportion 225 (broadly, “first portion”) and a retainer portion 227(broadly, “second portion”). Each of the fluid cover portion 225 and theretainer portion 227 has a generally cylindrical configuration, with thefluid cover portion 225 having a first diameter D1 that is smaller thana second diameter D2 of the fluid cover portion 225.

The fluid cover portion 225 has a generally cylindrical configurationwith a free end or distal end 226 facing the fluid chamber 105. Thefluid cover portion 225 extends from the distal end 226 to a flangeportion 228 of the retainer portion 227. In this regard, the fluid coverportion 225 of the integrated fluid cover 221 may be at least partiallyreceived within the end portion 106 of the fluid chamber 105 of thefluid end block assembly 101.

As shown, the flange portion 228 of the retainer portion 227 extendsradially outwardly from the fluid cover portion 225. The retainerportion 227 also includes a threaded portion 229 extending away from theflange portion 228 and that is configured to engage the interiorthreaded portion 127 of the fluid end block body 121 to mechanicallyconnect to the fluid end block body 121 as described above. In oneembodiment, the flange portion 228 of the retainer portion 227 mayextend radially outwardly from the threaded portion 229 so as to form aprotrusion or protuberance along the outer surface of the retainerportion 227.

As shown, the seal member 114 (broadly, “first seal member”) may bepositioned on the fluid cover portion 225 of the integrated fluid cover221 between the distal end 226 and the flange portion 228 of theretainer portion 227. In this regard, when the fluid cover portion 225of the integrated fluid cover 221 is at least partially received in theend portion 106 of the fluid chamber 105, the seal member 114 may bepositioned to sealingly engage interior surfaces of the fluid end blockbody 121. The seal member 114 may align or center the fluid coverportion 225 within the end portion 106 of the fluid chamber 105.

As also shown, the body 223 of the integrated fluid cover 221 defines atool engagement feature 231 at a free end or proximal end surface 232 ofthe retainer portion 227. The tool engagement feature 231 may be, forexample and without limitation, a polygonal (e.g., hexagonal) recesshaving a configuration complementary to that of an insertion or removalor securing tool, such as an Allen wrench or other driver whenpositioned to secure the integrated fluid cover 221. Optionally, thetool engagement feature may have a different configuration, for exampleand without limitation, a protrusion, without departing from thedisclosure.

In this regard, rotation of the integrated fluid cover 221 viaengagement of a tool with the tool engagement feature 231 may causerotation of both the fluid cover portion 225 and the retainer portion227 of the integrated fluid cover 221 due to the monolithic constructionof the body 223 of the integrated fluid cover 221. Such a configurationmay obviate and reduce the number of tools required for insertion,removal, and other maintenance of a fluid cover in which, for example, aretainer portion and a fluid cover portion are separate components.

Furthermore, the aforementioned monolithic construction of the body 223of the integrated fluid cover 221 may provide a higher mass single bodyas compared to the bodies of a fluid cover portion and a retainerportion provided as separate components of a fluid cover assembly. Inthis regard, the integrated fluid cover 221 provides enhanced materialintegrity, durability, and fatigue resistance in high pressure fluidenvironments.

For example, in a conventional fluid cover assembly that includes aseparately coupled fluid cover portion and retainer portion, cyclic highfluid pressures produced in a fluid pump system may result in a waterhammer effect in which impacts the fluid cover portion and which istranslated towards the retainer portion. These fluid pulsations may beinfluenced by factors such as pump operating pressure, pump crankshaftrotation speed, suction and discharge valve efficiency, and effectivefluid end chamber fill volume per plunger stroke. The fluidpulses/forces thus produce a constant vibration and wear on componentsof the fluid block assembly 101, and may cause relative movement of thefluid cover portion and the retainer portion, which may result, forexample, in wearing down or away of threaded portions or other couplingfeatures that may create a clearance gap (see FIG. 5) between the fluidcover portion and the separate retainer portion, backing out ordisengagement of the retainer portion from an end portion of a fluid endblock, the loss of seal integrity between the fluid cover portion andthe end portion of the fluid end block that may lead to leakage offluids from the fluid end block, etc.

Accordingly, the disclosed integrated fluid cover 221 is resistant towear and failure produced in the cyclic high pressure fluid environmentsin a fluid end block assembly 101 so as to reduce damage (e.g., wash,wear, cracking, etc.), reduce maintenance cycles and downtimes, minimizeconsumable components for the fluid end block assembly 101, ensure themaintenance of proper sealing contact with surfaces of the fluid endblock assembly 101, and reduce leakage from the fluid end block assembly101.

In addition, because the tool engagement feature 231 may be engaged toboth position and seat the fluid cover portion 225 in the end portion106 of the fluid end block assembly 101 as well as engage/couple theretainer portion 227 with the fluid end block body 121, the number oftools employed for installation/maintenance of components of the fluidend block assembly 101 may be reduced, as well as obviating the need toalign a separate fluid cover portion and a retainer portion.

Further, constructing or manufacturing the fluid cover portion 225 andthe retainer portion 227 into a single monolithic body of the fluidcover 221 may increase resistance to backing out and/or rotation of thefluid cover 221 during the rugged environment associated with operationof a fluid end. For example, with a separate fluid cover portion andretainer portion (see FIGS. 2A-3B), the fluid cover portion is subjectto translation forces towards and away from the retainer portion as aresult of what is known as the water hammer effect as will be understoodby those skilled in the art, and the retainer portion is subject torotational forces as a result of the retainer potion engaging the flangethereof. In contrast, the monolithic body of the fluid cover 221increases a mass resisting the water hammer effect. In addition, as theretainer portion 227 and the fluid cover portion 225 are monolithicallyformed together, the water hammer effect may be reduced by eliminatingmovement between the retainer portion 227 and the fluid cover portion225. Additionally, the frictional engagement between the monolithicfluid cover 221 may be increased to further resist the water hammereffect. For example, the seal member 114 frictionally engages the innersurface of the fluid end block body 121 which may increase resistance torotation of the fluid cover portion 225 relative to the fluid end blockbody 121 when compared to a non-monolithically formed fluid cover. Thisengagement further may increase a service life of the fluid cover 221and/or the fluid end block body 121 by reducing the number of componentparts and by reducing the risk of failure of this particular componentpart due to its construction as illustrated and described in theassociated embodiments.

Referring to FIGS. 7A and 7B, an integrated fluid cover according to asecond exemplary embodiment of the disclosure is generally designated321, and may be sealably coupled to the fluid end block assembly 101 ofa fluid pumping system 300 that may be otherwise similar to the fluidpumping systems described above, e.g., system 100. The integrated fluidcover 321 may have one or more features that are substantially similarto those described above with regard to the integrated fluid cover 221,and like or similar features are designated with like or similarreference numerals.

The integrated fluid cover 321 has a body 323 that is substantiallysimilar to the body 223 of the integrated fluid cover 221, except thatthe body 321 defines a machined or molded annular recess or groove 322along the fluid cover portion 225 adjacent the flange portion 228 of theretainer portion 227 and for at least partially receiving a seal member324 (broadly, “second seal member”) therein. The seal member 324 may bea flexible and/or resilient member, such as a polymeric (e.g., rubber)ring, for example and without limitation, an O-ring.

In this regard, the annular groove 322 may provide for an arrangement ofthe seal member 324 about the fluid cover portion 225 of the integratedfluid cover 321 that has a low or minimized profile, e.g., such that aminimal portion of the seal member 324 extends above the annular groove322. Accordingly, the annular groove 322 and seal member 324 cooperateto provide an arrangement of the seal member 324 that enhances afluid-resistant seal against the fluid end block body 121, but does notinterfere with proper placement or receipt of the fluid cover portion225 in the end portion 106 of the fluid chamber 105.

Furthermore, and with additional reference to FIG. 8, when the fluidcover portion 225 of the integrated fluid cover 321 is at leastpartially received with the end portion 106 of the fluid chamber 105,the seal member 324 may be compressed to a reduced profile, which mayalso have the effect of enhancing the sealing engagement of the sealmember 324 against the fluid end block body 121. As shown in FIG. 8, theflange portion 228 of the integrated fluid cover 321 is positioned toseat against an internal surface 128 of end portion 106 of the fluidchamber 105. Specifically, the seal member 324 may be configured toengage the chamfered surface 123 of the fluid end block body 121 suchthat the seal member 324 fills space or at least some of theinterstitial space between the retainer portion 225 and the fluid endblock body 121 as will be understood by those skilled in the art.

Referring now to FIG. 9, an integrated fluid cover according to a thirdexemplary embodiment of the disclosure is generally designated 421,which may be sealably coupled to the fluid end block assembly 101 of afluid pumping system 400 that may be otherwise similar to the fluidpumping systems described above, e.g., systems 100, 300. The integratedfluid cover 421 may have one or more features that are substantiallysimilar to those described above with regard to the integrated fluidcovers 221, 321 and like or similar features are designated with like orsimilar reference numerals.

The integrated fluid cover 421 has a body 423 that is substantiallysimilar to the body 223 of the integrated fluid cover 221, except thatthe body 421 includes a neck portion or shoulder 422 extending from asurface of the fluid cover portion 225 to the flange portion 228 of theretainer portion 227. In this regard, the shoulder 422 of the integratedfluid cover 421 has a tapered configuration that provides an obliqueannular surface positioned between the fluid cover portion 225 and theretainer portion 227 to substantially surround the fluid cover 421. Theoblique annular surface of the shoulder 422 increases in diameter as theshoulder 422 extends towards the flange portion 228 of the retainerportion 227.

Accordingly, and with additional reference to FIG. 10, when the fluidcover portion 225 of the integrated fluid cover 421 is at leastpartially received with the end portion 106 of the fluid chamber 105,the shoulder 422 may sealingly engage the chamfered surface 123 in africtional and/or wedged arrangement so as to provide an enhanced sealof the integrated fluid cover 421 against the fluid end block body 121that may resist fluid leakage from the fluid chamber 105. In oneembodiment, both the fluid end block body 101 and at least the shoulder422 of the integrated fluid cover 421 may be comprised of metal suchthat the interface of the shoulder 422 with the outer edge of the endportion 106 of the fluid chamber is a metal-to-metal interface thatprovides an enhanced seal. In some embodiments, the shoulder 422 mayinteract with the chamfered surface 123 to align or center theintegrated fluid cover 421 with the end portion 106 of the fluid chamber105.

The foregoing description of the disclosure illustrates and describesvarious exemplary embodiments. Various additions, modifications,changes, etc., could be made to the exemplary embodiments withoutdeparting from the spirit and scope of the disclosure. It is intendedthat all matter contained in the above description or shown in theaccompanying drawings shall be interpreted as illustrative and not in alimiting sense. Additionally, the disclosure shows and describes onlyselected embodiments of the disclosure, but the disclosure is capable ofuse in various other combinations, modifications, and environments andis capable of changes or modifications within the scope of the inventiveconcept as expressed herein, commensurate with the above teachings,and/or within the skill or knowledge of the relevant art. Furthermore,certain features and characteristics of each embodiment may beselectively interchanged and applied to other illustrated andnon-illustrated embodiments of the disclosure.

What is claimed is:
 1. A high-pressure, high power, reciprocatingpositive displacement fluid pumping system, the system comprising: ahigh-pressure, high power, reciprocating positive displacement pumpcomprising a pump plunger; a fluid end block assembly including a fluidend block body, a suction port, a discharge port, a pump bore positionedin and extending through the fluid end block body, and a fluid chamberpositioned in the fluid end block body and in fluid communication witheach of the suction port, the discharge port, and the pump bore, thefluid chamber having an open end portion, the pump plunger being movablypositioned in the pump bore to pressurize one or more fluids in thefluid chamber; and a fluid cover including a monolithic body having afirst portion and a second portion, the first portion being received inthe open end portion and sealingly engaged with the fluid end blockbody, the second portion being mechanically connected to the fluid endblock body, the fluid cover including a shoulder positioned between thefirst portion and the second portion, the shoulder engaged with thefluid end block body to seal the open end portion.
 2. The fluid pumpingsystem of claim 1, wherein the first portion has a first diameter, thesecond portion has a second diameter, and the first diameter being lessthan the second diameter.
 3. The fluid pumping system of claim 1,wherein the second portion comprises a threaded portion and a flangeportion, the flange portion being positioned adjacent the threadedportion and the first portion.
 4. The fluid pumping system of claim 3,wherein the fluid cover further comprises a first seal member positionedon the first portion and between the shoulder and a distal end of thefirst portion.
 5. The fluid pumping system of claim 4, wherein the fluidcover further comprises a second seal member positioned on the firstportion.
 6. The fluid pumping system of claim 5, wherein the firstportion of the fluid cover further comprises an annular groovepositioned adjacent the flange portion, the second seal member being atleast partially seated in the annular groove.
 7. The fluid pumpingsystem of claim 6, wherein the annular groove is positioned in theshoulder.
 8. The fluid pumping system of claim 1, wherein the shoulderhas an oblique annular surface extending from the first portion to thesecond portion and increasing in diameter as the shoulder extendstowards the second portion.
 9. The fluid pumping system of claim 8,wherein the fluid end block body has an interior chamfered surfacepositioned along interior peripheries of the open end portion of thefluid chamber, the oblique annular surface forming a seal against theinterior chamfered surface.
 10. The fluid pumping system of claim 3,wherein the fluid end block body has a threaded interior surfacepositioned along interior peripheries of the open end portion of thefluid chamber, the threaded portion engages the threaded interiorsurface to secure the fluid cover to the fluid end block assembly. 11.The fluid pumping system of claim 10, wherein the second portionincludes an end surface of the fluid cover, the end surface having atool engagement feature to engage with a securing tool when positionedto secure the fluid cover.
 12. The fluid pumping system of claim 11,wherein the fluid cover further comprises at least one seal memberarranged on the first portion.
 13. The fluid pumping system of claim 1,wherein the shoulder interacts with the open end portion to align thefluid cover with the open end portion.
 14. A fluid end block assemblyfor a high-pressure, high power, reciprocating positive displacementfluid pumping system, the fluid end block assembly comprising: a fluidend block body; a pump bore positioned in and extending through thefluid end block body; a plurality of ports including a suction port anda discharge port and providing access to and from the pump bore; a fluidchamber positioned in the fluid end block body, the fluid chamber beingin fluid communication with each of the suction port, the dischargeport, and the pump bore, the fluid chamber having an open end portion,the pump bore being positioned to receive a movable pump plunger topressurize one or more fluids in the fluid chamber; and a fluid coverconnected to the fluid end block body, the fluid cover including amonolithic body having a first portion and a second portion, the firstportion being received in the open end portion and configured to alignthe fluid cover with the open end portion, the second portion beingmechanically connected to the fluid end block body.
 15. The fluid endblock assembly of claim 14, wherein the first portion has a firstdiameter, the second portion has a second diameter, and the firstdiameter is less than the second diameter.
 16. The fluid end blockassembly of claim 14, wherein the second portion comprises a threadedportion and a flange portion, the flange portion is adjacent thethreaded portion and the first portion.
 17. The fluid end block assemblyof claim 16, wherein the fluid cover further comprises a seal memberpositioned on the first portion and between the flange portion and adistal end of the first portion.
 18. The fluid end block assembly ofclaim 17, wherein the seal member includes a first seal member, and thefluid cover further comprises a second seal member positioned on thefirst portion.
 19. The fluid end block assembly of claim 18, wherein thefirst portion of the fluid cover further comprises an annular grooveadjacent the flange portion, the second seal member being at leastpartially seated in the annular groove.
 20. The fluid end block assemblyof claim 14, wherein the body of the fluid cover further comprises ashoulder between the first portion and the second portion.
 21. The fluidend block assembly of claim 20, wherein the shoulder has an obliqueannular surface extending from the first portion to the second portionand increasing in diameter as the shoulder extends towards the secondportion.
 22. The fluid end block assembly of claim 21, wherein the fluidend block body has an interior chamfered surface positioned alonginterior peripheries of the open end portion of the fluid chamber, theoblique annular surface forming a seal with the interior chamferedsurface.
 23. The fluid end block assembly of claim 21, wherein theshoulder engages the open end portion of the fluid chamber to align thefluid cover with the open end portion.
 24. The fluid end block assemblyof claim 16, wherein the fluid end block body has a threaded interiorsurface positioned along interior peripheries of the open end portion ofthe fluid chamber, the threaded portion engages the threaded interiorsurface to secure the fluid cover to the fluid end block assembly. 25.The fluid end block assembly of claim 24, wherein the second portionincludes an end surface of the fluid cover, the end surface includes atool engagement feature for engagement with a securing tool whenpositioned to secure the fluid cover.
 26. The fluid end block assemblyof claim 25, wherein the fluid cover further comprises at least one sealmember arranged on the first portion.
 27. The fluid end block assemblyof claim 26, wherein the at least one seal member engages the open endportion of the fluid chamber to align the fluid cover with the open endportion.
 28. A fluid cover for being sealably engaged with a fluid endblock assembly of a high-pressure, high power, reciprocating positivedisplacement fluid pumping system, the fluid cover comprising: amonolithic body with a first portion and a second portion, the firstportion configured to be received in an open end portion of a fluidchamber of the fluid end block assembly and sealably engaged with thefluid end block assembly when connected thereto, the first portionconfigured to engage the open end portion of the fluid chamber to alignthe fluid cover with the open end portion, the second portion for beingmechanically connected to the fluid end block assembly.
 29. The fluidcover of claim 28, wherein the first portion has a first diameter, thesecond portion has a second diameter, and the first diameter being lessthan the second diameter.
 30. The fluid cover of claim 28, wherein thesecond portion comprises a threaded portion and a flange portionadjacent the threaded portion and the first portion.
 31. The fluid coverof claim 30, further comprising a seal member positioned on the firstportion and between the flange portion and a distal end of the firstportion.
 32. The fluid cover of claim 31, wherein the seal memberincludes a first seal member, and the fluid cover further comprises asecond seal member positioned on the first portion.
 33. The fluid coverof claim 32, wherein the first portion of the fluid cover furthercomprises an annular groove adjacent the flange portion, the second sealmember is at least partially seated in the annular groove.
 34. The fluidcover of claim 31, wherein the seal member is configured to engage theopen end portion to align the fluid cover with the open end portion. 35.The fluid cover of claim 28, wherein the body of the fluid cover furthercomprises a shoulder between the first portion and the second portion.36. The fluid cover of claim 35, wherein the shoulder is configured toengage the open end portion to align the fluid cover with the open endportion.
 37. The fluid cover of claim 35, wherein the shoulder has anoblique annular surface extending from the first portion to the secondportion and increasing in diameter as the shoulder extends towards thesecond portion.
 38. The fluid cover of claim 37, wherein the obliqueannular surface is configured to seal against an interior chamferedsurface of the fluid end block assembly positioned along interiorperipheries of the open end portion of the fluid chamber.
 39. The fluidcover of claim 30, wherein the threaded portion is configured to engagewith a threaded interior surface of the fluid end block assembly that ispositioned along interior peripheries of the open end portion of thefluid chamber to secure the fluid cover in the fluid end block assembly.40. The fluid cover of claim 39, wherein the second portion includes anend surface, the end surface includes a tool engagement feature isconfigured to be engaged by a securing tool when positioned to securethe fluid cover.
 41. The fluid cover of claim 40, further comprising atleast one seal member arranged on the first portion.
 42. A method ofoperating a high-pressure, high power, reciprocating positivedisplacement fluid pumping system, comprising: obtaining a fluid endblock assembly including a fluid end block body, a suction port, adischarge port, a pump bore positioned in and extending through thefluid end block body, and a fluid chamber positioned in the fluid endblock body and in fluid communication with each of the suction port, thedischarge port, and the pump bore, the fluid chamber having an open endportion; obtaining a high-pressure, high power, reciprocating positivedisplacement pump comprising a pump plunger and fluidly connecting thepump to the fluid end block assembly; aligning a fluid cover with thefluid end block by inserting a first portion of the fluid cover into theopen end portion, the first portion engaging the open end portion toalign the fluid cover with the fluid end block, the fluid coverincluding a monolithic body having the first portion and a secondportion; sealably connecting the fluid cover to the fluid end block bymechanically connecting the second portion to the fluid end block body;and operating the pump, the operating the pump comprises moving the pumpplunger in the pump bore to pressurize one or more fluids in the fluidchamber.
 43. The method of operating the fluid pumping system of claim42, wherein the first portion has a first diameter, the second portionhas a second diameter, and the first diameter being less than the seconddiameter.
 44. The method of operating the fluid pumping system of claim42, wherein the second portion comprises a threaded portion and a flangeportion adjacent the threaded portion and the first portion.
 45. Themethod of operating the fluid pumping system of claim 44, wherein thefluid cover further comprises a seal member positioned on the firstportion and between the flange portion and a distal end of the firstportion, and wherein aligning the fluid cover with the fluid end blockbody includes the seal member engaging the open end portion to align thefluid cover with the open end portion.
 46. The method of operating thefluid pumping system of claim 45, wherein the seal member includes afirst seal member, and the fluid cover further comprises a second sealmember positioned on the first portion.
 47. The method of operating thefluid pumping system of claim 46, wherein the first portion of the fluidcover further comprises an annular groove adjacent the flange portion,the second seal member being at least partially seated in the annulargroove.
 48. The method of operating the fluid pumping system of claim42, wherein the body of the fluid cover further comprises a shoulderpositioned between the first portion and the second portion.
 49. Themethod of operating the fluid pumping system of claim 48, wherein theshoulder has an oblique annular surface extending from the first portionto the second portion and increasing in diameter as the shoulder extendstowards the second portion.
 50. The method of operating the fluidpumping system of claim 49, wherein the fluid end block body has aninterior chamfered surface positioned along interior peripheries of theopen end portion of the fluid chamber, the method comprises positioningthe oblique annular surface in sealing contact against the interiorchamfered surface.
 51. The method of operating the fluid pumping systemof claim 44, the fluid end block body has a threaded interior surfacepositioned along interior peripheries of the open end portion of thefluid chamber, the method further comprises engaging the threadedportion of the fluid cover with the threaded interior surface to securethe fluid cover in the fluid end block body.
 52. The method of operatingthe fluid pumping system of claim 51, wherein the second portionincludes an end surface of the fluid cover, the end surface includes atool engagement feature, the method further comprises engaging the toolengagement feature with a tool to secure the fluid cover to the fluidend block body.
 53. The method of operating the fluid pumping system ofclaim 52, wherein the fluid cover further comprises at least one sealmember arranged on the first portion.
 54. A method of assembling a fluidpumping system, the method comprising: inserting a first portion of afluid cover into an open end portion of a fluid end block assembly suchthat the first portion engages the fluid end block assembly to align thefluid cover with the open end portion, the fluid cover comprising amonolithic body having the first portion and a second portion; andmechanically connecting the second portion of the fluid cover to theopen end portion of the fluid end block assembly such that the firstportion seals the open end portion of the fluid end block assembly. 55.The method of claim 54, wherein inserting the first portion of the fluidcover includes a seal member disposed about the first portion engagingthe open end portion to align the fluid cover with the fluid end blockassembly.
 56. The method of claim 54, wherein inserting the firstportion of the fluid cover includes a shoulder having an oblique annularsurface extending from the first portion to the second portion andincreasing in diameter as the shoulder extends towards the secondportion, the should engaging the open end portion to align the fluidcover with the fluid end block assembly.
 57. The method of claim 56,wherein mechanically connecting the second portion of the fluid cover tothe open end portion includes the shoulder forming a seal with the openend portion.
 58. The method of claim 57, wherein mechanically connectingthe second portion of the fluid cover to the open end portion includesthe shoulder forming a seal with an interior chamfered surface of theopen end portion.
 59. The method of claim 54, wherein mechanicallyconnecting the second portion of the fluid cover to the open end portionincludes threadably connecting the second portion to the open endportion.